Cheese and methods of making such cheese

ABSTRACT

Soft or firm/semi-hard ripened or unripened cheese products that has a native or modified starch and one or more additional ingredients are described. The additional ingredients may be chosen from a non-fat dry milk, a milk protein, an acidity regulator, an acid, an anticaking agent, an antifoaming agent, a coloring agent, an emulsifier, an enzyme preparation, a flavoring agent, a firming agent, a food protein, a gelling agent, a preservative, sequestrants, a stabilizer, a thickener, an oil, a fat, a cheese powder, a salt, a nutritional supplement, an acid, an enzyme, a neutraceutical, a carbohydrate, a vitamin, and a mineral. The starch, and additional ingredients may have a combined concentration of greater than 10%, by weight of the cheese product.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.13/584,392, filed Aug. 13, 2012 entitled CHEESE AND METHODS OF MAKINGSUCH CHEESE,” which is a continuation of U.S. patent application Ser.No. 12/772,628, filed on May 3, 2010 entitled “CHEESE AND METHODS OFMAKING SUCH CHEESE,” which is a continuation of U.S. patent applicationSer. No. 11/244,441, filed Oct. 4, 2005 entitled “CHEESE AND METHODS OFMAKING SUCH CHEESE,” which is a continuation of U.S. patent applicationSer. No. 11/121,537, filed May 3, 2005 entitled “CHEESE AND METHODS OFMAKING SUCH CHEESE,” which claims priority to U.S. Provisional App. No.60/568,029, filed May 3, 2004, and titled “SOFT OR FIRM/SEMI-HARDRIPENED OR UNRIPENED CHEESE AND METHODS OF MAKING SUCH CHEESES”, theentire contents of which are herein incorporated by reference for allpurposes.

This application is also related to the following U.S. patentapplications, all of which are incorporated herein by reference in theirentirety for all purposes:

-   1. U.S. Provisional App. No. 60/568,022, filed May 3, 2004, entitled    “Soft or Firm/Semi-Hard Ripened or Unripened Blended Cheeses and    Methods of Making Such Cheeses”, having attorney docket number    040179-000500US;-   2. U.S. Provisional App. No. 60/568,017, filed May 3, 2004, entitled    “Methods for Making Soft or Firm/Semi-Hard Ripened and Unripened    Cheese,” having attorney docket number 040179-000600US;-   3. U.S. patent application Ser. No. 11/122,283, filed May 3, 2005,    entitled “Blended Cheeses and Method for Making Such Cheeses,”    having attorney docket number 040179-000510US; and-   4. U.S. patent application Ser. No. 11/121,398, filed May 3, 2005,    entitled “Methods for Making Soft or Firm/Semi-Hard Ripened and    Unripened Cheese and Cheeses Prepared by Such Methods,” having    attorney docket number 040179-000610US.

BACKGROUND

Recently there has been an increase in the demand for cheeses that havewidely differing performance characteristics. This particular demand isdriven in part by the increasing variety of prepared foods in which suchcheeses are included. In fact, there often is a need for differentperformance qualities even for foods of the same general type because ofthe different ways cheeses are utilized or because the cheese is exposedto differing cooking environments or conditions. Pizzas illustrate thispoint well because there are so many different types of pizzas. Pizzas,for example, have widely differing crusts, including thick, thin, orsomewhere in between. The cheese can also be exposed or wrapped in theedge of the crust. Furthermore, the crust may be completely uncooked orit may be parbaked before being put in the oven with the cheese. Each ofthese variables potentially impacts the composition of the cheeserequired to provide satisfactory performance.

Demand for cheese with varying performance characteristics is alsodriven in part by the significant increase in the different types ofbaking equipment and conditions that are being used to prepare foodproducts containing cheese. Some baking operations, for instance,require relatively high oven temperatures (e.g., in the range of about350 to 950° F. (177-510° C.)) with short baking times (e.g., in therange of about 30 seconds to 15 minutes). Such conditions may be used,for instance, in an impingement oven when baking a pizza having a thincrust. Other ovens, such as deck ovens, in contrast, sometimes use arelatively long bake time (e.g., about 6 to 60 minutes) and acorrespondingly lower oven temperature (e.g., about 300 to 750° F. (149to 399° C.)). Instead of baking, some foods topped with or includingcheese are prepared by microwaving (e.g., about 1-6 minutes).

Consumer demand for cheeses with improved nutritional content (e.g.,nutritionally balanced, lower fat) has also increased the demand for newvarieties of cheese.

There are a variety of challenges to providing cheeses that have acomposition which satisfies the desired performance characteristics andnutritional qualities. For instance, it can be difficult to obtain thedesired concentration level of some ingredients in a cheese. Anotherproblem is developing a process that activates the latent functionalproperties of certain ingredients. Another problem is that many methodsfor preparing cheese involve the loss of significant quantities of somecheese components during processing. This can occur, for instance, whensuch cheeses undergo the heating and stretching process of the pastafilata process. Often the heating is conducted in heated water, whichcan remove significant amounts of cheese ingredients.

In view of the high demand for cheese and the foregoing shortcomingsassociated with some existing methods for preparing such cheeses withthe desired performance characteristics, there thus remains a need foradditional methods for preparing cheeses of these types.

SUMMARY

Methods for preparing a variety of cheese products are disclosed.Systems for preparing such cheeses and slurries, and cheeses produced bythe disclosed methods are also provided.

Some of the cheese processing methods involve initially providing aslurry that comprises one or more ingredients that one seeks toincorporate into the final cheese product. The slurry is then combinedwith a cheese precursor to form an admixture. The resulting admixture isthen processed to form the final cheese product. The slurry can becombined with a variety of cheese precursors including a cheese curdingredient, a mixture of cheese curd ingredients, a coagulum, a cheesecurd, a heated mass of cheese (e.g., a heated mass of cheese curd), adry mixed cheese, or a same day diced cheese. In some methods, theslurry lacks a cheese curd. The slurry in other methods lacks one ormore analog cheese ingredients (e.g., an oil, a fat, a protein, astarch, a sequestrant and/or a salt).

A variety of ingredients can be incorporated into the slurry including,but not limited to, a nonfat dry milk, a milk protein, an acidityregulator, an acid, an anticaking agent, an antifoaming agent, acoloring agent, an emulsifier, an enzyme preparation, a flavoring agent,a firming agent, a food protein, a gelling agent, a preservative,sequestrants, a stabilizer, a starch, a thickener, an oil, a fat, acheese powder, a salt, a nutritional supplement, an acid, an enzyme, aneutraceutical, a carbohydrate, a vitamin, and a mineral. Examples mayfurther include procream, whey cream, a dairy solid, and foodstuffs ofvegetable, fruit and/or animal source. The foodstuffs may include fruit,vegetables, nuts, meat, and spices, among other foodstuffs.

In some methods, the slurry is processed before it is combined with thecheese precursor. Typical processing steps include one or more of thefollowing processes: heating the slurry, subjecting the slurry to highshear conditions, homogenizing the slurry and adjusting the watercontent of the slurry.

Other methods for preparing a cheese involve combining a slurry with aheated mass of cheese curd to form an admixture and then shaping andcooling the admixture to form the final cheese product. In some of thesemethods, the slurry contains sufficient starch, nonfat dry milk, gum orcellulose such that the cheese has one or more of the followingcharacteristics (i) a starch concentration of about 0.5 to 20 wt %, or(ii) a nonfat dry milk concentration of about 0.5 to 25 wt %, or (iii) agum or cellulose concentration of about 0.5 to 20 wt %.

Methods for preparing heated slurries that can be used in thepreparation of cheeses are also described herein. Some of these methodsinvolve blending together a liquid and one or more GRAS ingredients toform a slurry and then processing the slurry. Processing typicallyinvolves heating the slurry to a temperature of about 90° F. to about300° F. and performing one or more additional processing steps selectedfrom the group consisting of subjecting the slurry to high shearconditions, homogenizing the slurry and adjusting the moisture contentof the slurry.

Various systems for manufacturing a cheese product are provided. Some ofthese systems include a slurry preparation system that includes (i) ablender adapted to blend a liquid and one or more generally recognizedas safe (GRAS) ingredients together to form a slurry, and (ii) a cookerthat is operatively disposed to receive the slurry from the blender andadapted to heat the slurry to a temperature of about 90° F. to about300° F. These systems also include a first mixer operatively disposed toreceive the slurry from the slurry preparation system and adapted to mixthe slurry with a heated mass of cheese curd to form an admixture. Afinal processing system is also included which is operatively disposedto receive the admixture and adapted to form a final cheese product.

Such systems can optionally also include a slurry mixing and moisturecontrol subsystem. These subsystems include one or more of the followingunits: (i) a shear pump adapted to subject the slurry to high shearconditions; (ii) a homomgenizer adapted to homogenize the water and theone or more ingredients in the slurry; and (iii) an evaporator adaptedto adjust the water content of the slurry to about 5-95% by weight. Thesubsystem in these systems is in communication with the cooker and thefirst mixer and the units within the subsystem are in fluidcommunication.

The arrangement of some subsystems is such that the shear pump isoperatively disposed to receive the slurry from the heater and is incommunication with the homogenizer. The homogenizer in turn isoperatively disposed between the shear pump and the evaporator andadapted to receive the slurry from the shear pump. The evaporator isoperatively disposed to receive the slurry from the homogenizer and incommunication with the first mixer.

Some systems also include a second dry or wet mixer that (i) is adaptedto heat and knead a mass of cheese curd that is introduced therein, and(ii) is in communication with the first mixer such that the heated massof cheese that is produced in the first mixer can be transported to thesecond mixer.

Slurry preparation systems are also provided. Certain of these systemsinclude a (a) blender adapted for preparing a slurry, the slurrycomprising water and one or more generally recognized as safe (GRAS)ingredients, (b) a cooker adapted to heat the slurry to a temperature ofabout 90° F. to about 300° F.; and (c) a slurry mixing and moisturecontrol subsystem. The subsystem itself includes one or more of thefollowing units (i) a shear pump adapted to subject the slurry to highshear conditions; (ii) a homogenizer adapted to mix the water and theone or more ingredients in the slurry; and (iii) an evaporator unitadapted to adjust the water content of the slurry to about 5-95% byweight. In such subsystems, the units making up the subsystem are influid communication and the blender, heater and slurry mixing andcontrol subsystem are in fluid communication.

A variety of cheeses (e.g., a soft or firm/semi-hard ripened orunripened cheese product) are provided. Some of these have one or moreof the following characteristics (i) a nonfat dry milk concentration ofgreater than 11% by weight, or (ii) a starch concentration of greaterthan 11% by weight, or (iii) a gum or cellulose concentration of greaterthan 11% by weight. Some of these have one or more of the followingcharacteristics (i) a nonfat dry milk concentration of greater than 10%by weight, or (ii) a starch concentration of greater than 10% by weight,(iii) a gum or cellulose concentration of greater than 10% by weight.

Slurries of different compositions are also provided that can be used inthe preparation of cheese. Some slurries, for instance, have atemperature of about 90° F. to about 300° F. and have one or more of thefollowing characteristics (i) a starch concentration of at least 12 wt%, or (ii) a dairy solid concentration of at least 12 wt %.

A variety of cheeses (e.g., a soft or firm/semi-hard ripened orunripened cheese product) are provided. Some of these have one or moreingredients added in the form of (i) a slurry of varying composition,and/or (ii) a dry powder used in the preparation of cheese. Somecheeses, for instance have ingredients added via the slurry such that0.5-25% of an ingredient is added in the final cheese. Other cheeses mayhave ingredients added via a dry powder such that 0.5 to 15% of aningredient is added in the final cheese. And still other cheese may haveboth a slurry and a dry powder added simultaneously such that thecombination of slurry and powder result in ingredient amounts of about0.5 to 25%.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts one example of a general method for making a cheeseproduct using a slurry.

FIGS. 2A-2C show different examples of general methods for making acheese product using a slurry.

FIGS. 3A and 3B show in schematic form other examples of certain methodsthat are disclosed herein to prepare cheese. FIG. 3A depicts a method inwhich a slurry is combined with a heated mass of cheese. FIG. 3B depictsa method in which a slurry is combined with a curd or curd precursor.

FIGS. 4A-4E depict various exemplary systems for preparing various typesof cheese. FIG. 4A shows the major subsystems in certain manufacturingsystems. FIG. 4B shows a system that can be used to prepare a cheese bycombining a slurry with a heated cheese mass. FIG. 4C shows anothersystem that is designed to prepare a cheese in which the slurry iscombined with a curd or curd precursor. FIGS. 4D and 4E illustraterespectively examples for how ingredients can be introduced into acheese in a parallel or serial fashion.

FIGS. 5A-B show cross sectional samples of finished cheeses.

DETAILED DESCRIPTION I. Definitions

A “soft or firm/semi-hard cheese” as used herein generally includescheeses that have a percentage moisture on a fat free basis (MFFB) ofabout 54% or more, by weight. The term includes firm/semi-hard cheesesthat have a MFFB, for example, of about 54% to about 80%, by wt., andchesses with a MFFB, for example, of about 58% to about 75%, by wt. Theterm may also include soft cheeses with a MFFB of greater than about60%, by wt. The term encompasses a variety of well known cheesesincluding, but not limited to, Colby, Havarti, Monterey Jack,Gorgonzola, Gouda, Cheshire and Muenster, which are examples of“firm/semi-hard cheeses.” Also included in the term are popular “softcheeses” such as Mozzarella, cream cheese, and cottage cheese. A varietyof mozzarella cheeses are included by the term; these can be in the softor firm/semi-hard category, or in between the two, depending upon theirmoisture content. Standard mozzarella, for example, is a soft cheese,part-skim mozzarella is between soft and firm/semi-hard, andlow-moisture mozzarella and low-moisture part-skim mozzarella are bothdesignated as firm/semi-hard cheeses. The term soft or firm/semi-hard asused herein includes cheeses meeting the CODEX definition of a soft orfirm/semi-hard cheese. The term also includes soft or firm/semi-hardcheeses as defined by other local, regional, national or internationalagencies or organizations.

Cheeses within the “soft or firm/semi-hard” category as defined hereincan be prepared using a variety of methods, including conventionalmethods, as well as by “alternative make” provisions. The term includes,for instance, cheeses made by a process in which a cheese curd is heatedand kneaded to improve the stretchability or stringiness of the finalcheese, provided the cheese falls within the MFFB parameters set above.This process and related processes are sometimes referred to as a pastafilata process of manufacturing. Cheeses made by this process are knownunder a variety of names, including mozzarella, pasta filata, provolone,Mexican style, scamorze, and pizza cheese. Cheeses made by alternativemake procedures are prepared by alternative methods of making cheeses,so long as the procedure produces a cheese having the same physical andchemical properties of the type of cheese made by a specified process(e.g., a process specified by a regulatory agency) and falls within theMFFB parameters set forth above.

The “soft” and “firm/semi-hard” cheeses that are provided includestandard and non-standard cheeses and cheese products having theforegoing moisture characteristics. Standard cheeses are those thatsatisfy the standards as set forth by a regulatory body with respect toa particular type of cheese. A non-standard cheese is one whosecomposition does not meet the standard. A soft or firm/semi-hard cheesecan also be a processed cheese. A soft or firm/semi-hard cheese can alsobe ripened or unripened.

“Mozzarella” cheese has a minimum milkfat content of 45% by weight ofthe solids and a moisture content of more than 52% but not more than 60%by weight. “Low-moisture mozzarella” cheeses have a minimum milkfatcontent of 45% by weight of the solids and the moisture content is morethan 45% but not more than 52% by weight. “Part-skim mozzarella” has amoisture content of more than 52% but not more than 60% by weight, and amilk fat content that is less than 45% but not less than 30% calculatedon the solids basis. “Low-moisture part-skim” mozzarella has a moisturecontent of more than 45% but not more than 52% by weight and a milkfatcontent, calculated on the solids basis, of less than 45% but not lessthan 30%. Further details regarding these various mozzarella cheeses isprovided by 21 C.F.R. §1.33.155-133.158.

The term “cheese precursor” as used herein refers broadly to anyingredient that is used to prepare a cheese curd, mixtures of suchingredients and subsequent processed forms of the cheese curd other thanthe final cheese product. Examples of cheese precursors that areingredients include, but are not limited to, unpasteurized milk(sometimes referred to in the industry as “raw milk”), the growth mediumand bacteria used in the cheese making process (sometimes referred to inthe industry as “starter”), and cream. Mixtures of such ingredients arealso included. One specific example of such mixtures is “vat liquid”,which is a term used to refer to a combination of pasteurized milk,starter and cream. The term also includes coagulum, cheese curd, andprocessed cheese curd (e.g., curd that has been heated and/or stretchedto form a homogeneous mass of cheese).

The term “cream” means the liquid milk product high in fat separatedfrom milk which may have been adjusted by adding thereto: milk,concentrated milk, dry whole milk, skim milk, concentrated skim milk,nonfat dry milk or other GRAS ingredients. “Whey cream” is the liquidmilk product high in fat separated from whey (cheese, casein, or other),which may have been adjusted by adding thereto: whey, concentrated whey,dry whey, or other GRAS ingredients. “Procream” is the liquid milkproduct high in fat collected as retentate from a whey filtrationprocess such as microfiltration which may have been adjusted by addingthereto: whey, concentrated whey, dry whey, or other GRAS ingredients.

The term “curd precursor” refers to any soft or firm/semi-hard cheeseingredient, mixture or composition that exists or is formed prior toformation of the cheese curd. The term thus includes, for example, rawmilk, starter, cream, cheese vat liquids and coagulum.

II. Overview

Methods for preparing a variety of different types of cheeses areprovided, including for example, soft or firm/semi-hard ripened andunripened cheese. The methods that are provided generally involvecombining a slurry with a cheese precursor to form an admixture that issubsequently processed to form the final product. The slurry typicallycontains a liquid (e.g., water, milk and/or cream) and one or moreingredients (added either as a liquid or a dry powder, for example) thatare selected in accord with the final cheese product that is desired.Once the slurry and cheese precursor are thoroughly mixed together, theresulting admixture is processed to yield the final soft orfirm/semi-hard cheese product. Systems for preparing such cheeses andslurries are also disclosed.

The methods, for instance, can be used to introduce various ingredients,either in the slurry and/or with another component of the cheese, tocontrol: 1) melt and flowability of the final cheese product, which is ameasure of how well the cheese melts and flows into a homogenous mass,preferably with little or no individual shreds of cheese stilldetectable; 2) stretch, which is measure of the ability of the cheese toform interconnected strings when the heated cheese is pulled; 3)texture, which is a measure of chewiness and smoothness; 4) coloring,which is a measure of the actual color of the melted cheese; 5) blistercharacteristics, which may include size, color and extent of coverage;and/or 6) nutritional composition.

The use of a slurry in the methods disclosed herein may also providesignificant improvements in yield. A typical cheese process in its basicapproach involves acidifying and coagulating milk to form a coagulumthat contains cheese curd and whey, removing the whey from the curd, andthen processing the curd into a final cheese product. The whey that isremoved in conventional cheese manufacturing often contains manydissolved or suspended ingredients, which often means that a significantquantity of dissolved substances (e.g., protein, fat, carbohydrate andminerals) are lost when the whey is separated from the curd. If anyingredients are added before the whey is separated from the curd, manyof these ingredients, because they are at least partially soluble in thewhey fraction, are also lost.

As a specific example of the extent of this problem, for each 100 poundsof milk that is used to prepare a cheese, it is not uncommon usingconventional cheese manufacturing techniques to only be able to produce10 pounds of cheese. By using some of the slurry-based methods that aredisclosed herein, the yield can be increased in some instances to about15, 18, 20 22, or 50 or more pounds of cheese for each 100 pounds ofmilk. Thus, with some methods, the yield can be increased by 1.5-2 timesor more. The increase in yield is due in part to the use of slurriesthat allow ingredients to be integrated into a precursor of the finalcheese product when essentially all the ingredients in the slurry areretained, as compared to earlier in the process in which a significantproportion of added ingredients are lost.

One approach is to add the nonfat dry milk to the milk that is used toprepare the cheese. If added at this stage, it is not uncommon for about75% of the nonfat dry milk to be lost, including proteins, lactose andminerals in the nonfat dry milk. If the nonfat dry milk is insteadincorporated into some of the slurries that are provided and theresulting slurry mixed, for instance, into a cheese precursor (e.g., ahomogenized mass of cheese curd) as described herein, much, if notessentially all, of the nonfat dry milk may be incorporated into thefinal cheese product.

In some methods, the slurry is processed so it is in a form that confersuseful properties on the final cheese product and/or facilitatespreparation of the cheese. Some methods, for instance, utilize a heatedslurry that may also have been sheared and/or homogenized. Suchprocessing can influence the performance of the final cheese product invarious ways. For example, this processing can be used to achieve higherconcentrations of certain ingredients in the final cheese product ascompared to traditional approaches. Without intending to be bound bytheory, it is believed that the shearing and homogenization process canreduce particle size of the components of some cheese ingredients. Theseresulting particles because of their reduced size are thus better ableto become incorporated into the overall cheese matrix, thereby allowingmore ingredient to be introduced into the final cheese product.

The reduced particle size also makes it easier to remove excess waterduring the manufacturing process to the level desired in latermanufacturing stages. The ability to control water content is animportant factor in being able to regulate the stability of cheese andthus its shelf life. Reduced particle size also facilitates forming acompact cheese that can be easily processed (e.g., shredded, sliced, ordiced). Shearing and homogenization can also be important in reducingthe viscosity of the slurry, which aids in various processing steps(e.g., transport of the slurry).

Use of a slurry that has been heated, sheared and/or homogenized duringthe manufacturing process also is useful in activating, exposing thefunctionality and/or in hydrating the ingredients, such that theingredient has different properties than the corresponding unheatedingredients. As a specific example, it can be difficult to incorporatenonfat dry milk into a cheese as a dry powder in certain cheesemanufacturing methods because the nonfat dry milk never becomes fullyhydrated. This makes the nonfat dry milk susceptible to burning whencooked, for example. By using certain of the slurry-based methodsdisclosed herein, ingredients such as nonfat dry milk can be betterhydrated, thus mitigating against the burning problem. The hydration ofother ingredients can have other beneficial results.

Some methods also involve a process in which the water content of theslurry is adjusted. This is useful because the water content in a cheeseis an important factor in stability, shelf life and the ability toslice, shred and dice the final cheese product.

In sum, the use of slurries to introduce ingredients into cheeses atcertain stages of the manufacturing process can be used to help tailorthe performance and nutritional characteristics of the final cheeseproduct.

III. Methods for Preparing Soft or Firm/Semi-Hard Cheese

A. General

FIG. 1 provides a flow diagram that summarizes one general scheme 10 forpreparing a cheese product, such as a soft or firm/semi-hard cheese. Asthis figure indicates, some methods involve providing a slurry 12 thatcontains one or more ingredients. The ingredients in the slurry areselected to in accordance with the final cheese product that is desiredand are described in detail below. The slurries in the methods describedherein typically do not contain curd and thus lack cheese curd, but may,for example, instead include other ingredients selected to impart ataste, performance and/or nutritional characteristic on the final cheeseproduct (e.g., mouthfeel, blister size, melt characteristic, texture orcolor). Some slurries also do not contain ingredients that are commonlyused in the preparation of analog cheese. Methods using such slurriesthus typically omit one or more or all of the following: an oil, a fat,a protein, a starch, a sequestrant and a salt. Other methods, however,utilize slurries that contain some or all of these ingredients. Theslurry is combined 14 with a cheese precursor to form an admixture. Thisadmixture is then processed 16 to form the final cheese product.

Another example of a general method is shown in FIG. 2A. This process 20involves providing 22 a slurry that contains one or more ingredients andproviding 24 a cheese precursor. In this particular method, the cheeseprecursor (e.g., milk, cream, coagulum and/or curd) is mixed 26 with oneor more ingredients. This mixture is then combined 28 with the slurry toform an admixture. Additional ingredients can subsequently be added 30to the admixture, thus providing another opportunity to control thecomposition of the final cheese product. The admixture is then subjectedto final processing 32 to obtain the desired cheese product. Althoughthe method in FIG. 2A includes two processes in which additionalingredients are added (i.e., processes 26 and 30), other methods includeonly one or neither of these processes.

FIG. 2B presents a variation of the general method shown in FIG. 2A. Inthis method 30, a cheese precursor is provided 24, mixed 26 with one ormore ingredients and then combined 28 with a slurry 22 to form anadmixture. In contrast to the method shown in FIG. 2A, however, theresulting admixture is then divided 29 into multiple portions (e.g., afirst and second admixture). Each admixture is then processedseparately. For instance, a first ingredient or set of ingredients canbe added 30 a to the first admixture portion and the resulting mixturefurther processed 32 a to form a first cheese product. A secondingredient or set of ingredients (typically different from the firstingredient or ingredient set) is then added 30 b to the second admixtureportion and then subjected to further processing 32 b to form a secondfinal cheese product. This approach is useful, for instance, to preparedifferent cheeses with similar base compositions but somewhat differentingredients. Although FIG. 2B shows a method in which the initialadmixture is divided into only two separate portions, it should beunderstood that the initial admixture could be divided into a greaternumber of portions with parallel processing of each portion as indicatedin FIG. 2B. Further, although the method in FIG. 2B shows ingredientsbeing added 26 to the cheese precursor before the cheese precursor andslurry are mixed, this step need not be performed in all methods.

A second variation of the method shown in FIG. 2A is depicted in FIG.2C. In this method 40, the providing 22, 24 and mixing 26 processes areas described with respect to FIG. 2A. In this particular method,however, once the slurry and cheese precursor have been combined 28,multiple ingredients are added in a serial process (as compared to theparallel process illustrated in FIG. 2B). Thus, for example, one or morefirst ingredients are added 30 to form an initial admixture and then oneor more second ingredients added 31 to form a final admixture, which issubsequently further processed 32 to form the final cheese product. Thefirst and second ingredient can be the same or different. The first andsecond ingredient can also be a single ingredient or a plurality ofingredients. It should further be understood that although FIG. 2Cillustrates a method in which there are two serial additions ofingredients that more serial additions could be made.

Methods of the general type shown in FIG. 2C are useful, for example,when separate additions of ingredients allows for improved incorporationinto the cheese (e.g., adding all the ingredients at once may preventthe ingredients from becoming fully mixed into the admixture).

The various primary processes involved in the methods that are provided,such as those described in FIGS. 1 and 2A-2C, are discussed in detail inthe following sections.

1. Slurry Preparation and Pre-Mixing Process

The process of providing the slurry can comprise several aspects. Somemethods, for example, generally involve blending a liquid (e.g., water,oil, milk and/or cream) and one or more ingredients to form the slurry.The resulting slurry is then subjected to a pre-mixing process to adjustthe slurry to a form that will integrate well with the cheese precursorwith which the slurry is mixed. The pre-mixing process usually includescooking the slurry, typically to about 90-300° F., 90-293° F. or100-250° F. (38-121° C.), but this is not mandatory. This pre-mixingprocessing also optionally includes one, two or all of the followingprocesses: (1) subjecting the slurry to high shear conditions, (2)homogenizing the slurry, and/or (3) adjusting the water content of theslurry, usually to about 5-95%, or 15-80% by weight. As noted above,these processes are helpful in controlling processing parameters and theultimate performance characteristics of the final cheese product.

Different methods can incorporate different combinations of two or allthree of the foregoing optional processes. So, for example, in somemethods, the pre-mixing processing involves (1) and (2) but not (3).Other processes include (1) and (3) but not (2). Still other pre-mixingprocesses include (2) and (3) but not (1). And still other processesinclude (1), (2) and (3). The other remaining combinations can also beutilized depending upon the particular requirements of an application.In some instances, it is sufficient to simply shear the slurry withouthomogenizing it. But the pre-mixing process may involve both, in whichcase the slurry is first typically sheared and then homogenized,although the order can be reversed.

In some methods, some of the pre-mixing processes are optionally carriedout at the same time (e.g., subjecting the slurry to high shearconditions while homogenizing the slurry; or heating the slurry whilesubjecting it to high shear conditions and/or homogenizing the slurry).Cooking can optionally be performed during the shearing and/orhomogenizing. In general, however, the pre-mixing processing stepsconclude by adjusting the water content of the slurry.

Some ingredients need to be subjected to high shear conditions to becomefunctional (e.g., hydrated or converted to a form that displaysfunctional binding groups). High shear conditions as used hereingenerally refers to conditions in which 10,000 to 500,000 s⁻¹ of shearis applied. In some methods, the slurry is typically sheared by ahigh-shear mixer or colloid mill, at a temperature of about 90 to 293°F. (15 to 82° C.) for about 0.01 to 0.5 seconds.

Homogenization of the slurry, if performed, generally involves theprocess of reducing the particle size of fluid products under conditionsof extreme pressure, shear, turbulence, acceleration and impact, to makethem more stable and have a better texture. The effect is typicallyachieved by forcing the slurry through a special homogenizing valve at avery high pressure. Homogenization can be done in one or multiple steps.For most methods, two steps are sufficient. It is common that the mainhomogenization takes place in the first homogenization valve and a mildhomogenization in the second valve. The second homogenization valve canenhance the product quality. This step, for example, can break downnewly formed fat globule clusters formed directly after the first valvedue to re-agglomeration. Homogenization is usually conducted at atemperature of about 90-293° F. (32-145° C.) or 100-250° F. (38-121° C.)for about 0.01 to 0.5 seconds.

As indicated above, if the water content of the slurry is adjusted, themoisture content is generally adjusted to about 5-95 percent, in someinstances from about 15-80 percent, in other instances 20-75%, and instill other instances 30-60%. After such processing, the slurry that ismixed with the cheese precursor, generally has a temperature of about100-180° F. (37-83° C.), or about 120-165° F. (48-74° C.). It alsotypically has a viscosity of 1000 to greater than about 1,000,000centipoise in this temperature range.

2. Exemplary Methods for Providing Cheese Precursor

As noted above, various cheese ingredients or mixtures thereof can serveas the cheese precursor. Other cheese precursors include compositionsformed during processing of the starting ingredients, including, forexample: 1) the pasteurized milk; 2) cheese milk formed by theacidification of the pasteurized milk; 3) the coagulum formed during thecoagulation process; and/or 4) the cheese curd.

Cheese curd can be prepared, for example, from pasteurized cow's milk,buffalo milk, goat's milk, or other milk source (e.g., concentratedmilk, reconstituted milk or milk protein powders). The milk is acidifiedto form cheese milk. The acidification step can be performed eithermicrobially or directly, or by a combination of both microbial anddirect acidification. Microbial acidification is accomplished by theaddition of a starter culture of one or more lactic acid-producingbacteria to the milk, and then allowing the bacteria to grow andmultiply. When making a mozzarella variety cheese, a bacterial starterculture composed of coccus, rods, or a combination of both is preferablyused. In some methods of acidification, an acid added as a processingaid, such as acetic acid (e.g., vinegar), phosphoric acid, citric acid,lactic acid, hydrochloric acid, sulfuric acid, or glucono-delta lactone(GdL), lactobionic acid, etc., is added to standardize pH and isfollowed by addition of microbial starter to complete the acidificationprocess.

Following addition of the microbial and/or GRAS acids, the cheese milkis coagulated to form a coagulum that consists of cheese curd and whey.Rennet, or another suitable enzyme, is typically added to the milk toenhance the coagulation activity. The resulting coagulum is cut and thewhey drained off to obtain the cheese curd. The curd can optionally bescalded (cooked) for about 0.08 to 1.0 hours at about 86-120° F. (30-49°C.)° C.

When dairy milk is used as a precursor, the sweet cream fraction of themilk, or a portion thereof, may be separated and replaced by other typesof creams and/or fats prior to acidification. For example, the sweetcream may be replaced by whey cream and/or pro-cream (i.e., a mixture ofprotein and cream) that is included with the whey fraction that isseparated from the cheese curd. The replacement of the dairy sweetcream, or a portion thereof, with the whey cream and pro-cream reduceswaste by making use of the whey cream and pro-cream, as well as makingthe higher value sweet cream available for sale in the marketplace.

In some methods, the cheese curd is heated and kneaded in a cooker/mixerto form a heated mass of cheese curd (also referred to simply as aheated mass of cheese). The heating and kneading process is generallydone at a temperature of about 120-180° F. (48-82° C.) for a time ofabout 1-15 min. Typically, the resulting mass has a temperature fromabout 120-150° F. (48-66° C.). The heating and kneading process can beconducted simultaneously or separately.

The heating and kneading process is generally conducted under low shearconditions. Heating can be conducted, for instance, in a kneadingmixer/extruder via 1) immersion in hot water or brine, 2) direct steaminjection, 3) indirect heating via an indirect heat exchanger, and/or 4)by microwave. The steam injection option generally involves releasinglive steam into the kneading and stretching chamber. When live steam isused to heat the curd, the steam condensate is absorbed by the curd andforms part of the final mass of cheese. When using live steam in themixer/cooker, typically the water content of the curd immediately priorto entering the mixer/cooker is about 45 to 65 wt. %, and sufficientsteam is released into the kneading and stretching chamber such that thewater content of the mass of cheese immediately after exiting themachine is up to about 5 percentage points higher, e.g., about 0.5 to 10points higher. Often, it will be about 2.5 to 8.5 points higher. So, forexample, if the water content of the curd entering the machine is 45 wt.%, then usually the amount of injected steam that is used to bring thecurd up to the necessary temperature to obtain a homogenous mass ofcheese will be an amount that raises the water content to no more thanabout 55 wt. %. Indirect heating can be accomplished, for example, byconduction, through the wall of the kneading and stretching chamber,e.g., by use of a hot water jacket.

In some methods, heating and kneading can be performed in the absence ofany exogenous water. By “exogenous water” is meant water that is used tobathe the curd and which is subsequently separated from the homogenouscheese mass that is formed. A shortcoming of the use of exogenous waterduring the heating and kneading process is that, when the water isseparated, valuable protein, fat, and other solids that otherwise wouldbe bound up in the finished cheese are removed. Various cookers can beused to heat the cheese curd in this fashion. One option is theRotaTherm™ cooker available from Gold Peg International Pty. Ltd.(Moorabbin, Vic, Australia).

Kneading is often accomplished by working the heated cheese curd withpressure via single or dual helical intermeshing screws. The whole ofthe heating and kneading step is sometimes referred to as aplasticization or pasta filata process, which refers to the heating ofcurd to around 120-155° F. (48-69° C.) and kneading the hot curd.Successful plasticization of the curd requires that the viscoelasticparacasein matrix undergoes limited flow and stretches without breaking.Plasticization is believed to be accompanied by changes at amicrostructure level within the curd, including partial aggregation andtightening of the paracasein gel matrix followed by formation of linearparacasein fibers with high tensile strength. The cheese fat coalescesinto elongated pools entrapped between paracasein fibers showing theirsame orientation. This process aids in obtaining the properfunctionality in the final product.

The heating and kneading process described herein ensure complete mixingof the heated curd. This is important because incomplete mixing resultsin the separation of fat and water and the loss of these ingredients, aswell as other such as fat, lactose and minerals.

3. Mixing of Slurry and Cheese Precursor

The slurry is combined with a cheese precursor to form an admixture. So,for instance, the slurry can be combined at any stage along the processfor preparing a soft or firm/semi-hard cheese as outlined in thepreceding section. Mixing of the slurry with a cheese precursor can beaccomplished using standard mixing apparatus that are known in theindustry.

In some methods, the slurry is mixed with a heated mass of soft orfirm/semi-hard cheese that has undergone the heating and kneadingprocess that is associated with the pasta filata process. For ease ofreference, cheese curd that has undergone such a heating and kneadingprocess is simply referred to herein as a “heated cheese mass.” Inmethods such as this, the mixing typically is performed at a temperatureof about 120 to about 170° F. (49-77° C.). The temperature in someapplications is relatively high, such as between 150-170° F. In othermethods, the temperature is at or slightly below that of pasteurization(65° C., 150° F.), for example in the range of about 120-150° F. (49-65°C.). Mixing is usually conducted for about 2-15 or 5-10 minutes. Mixingis generally performed under low shear conditions.

Combining the slurry with the heated cheese mass is a useful approachbecause the slurry can be fully worked into the heated cheese mass withminimal loss of ingredients during the mixing process and subsequentprocessing steps. This thus is useful in reducing waste flow from themanufacturing process, thereby conferring significant cost benefits andreducing waste disposal issues.

4. Optional Addition of Ingredients

Some methods optionally involve the further addition of ingredients atpoints along the cheese preparation process other than the blending ofingredients with a liquid to form the initial slurry. Ingredients can beadded, for example, to the cheese precursors listed above (e.g., to thecurd ingredients, the coagulum and/or the cheese curd). Theseingredients can be added as liquids and/or powders.

In certain methods, ingredients are added to the heated cheese mass, theprocessed slurry (e.g., after the slurry has been heated, homogenized,sheared and/or the water content adjusted) or the admixture formed oncethe heated slurry and heated cheese mass are mixed together. Theseingredients are often added in a dry form (e.g., as a powder), but insome instances can be added in liquid form. Powdered solids can be addedusing any of a number of conventional approaches, including sprinklingthe solids onto the cheese mass, usually across the entire surface ofthe cheese mass and typically after application of agents or ingredientsin liquid form, if any. Liquid agents or ingredients can be sprayed downonto the surface of the cheese mass as it passes through the mixingchamber, usually in a spray that covers substantially the entire surfaceof the cheese.

5. Final Processing

Once the slurry and cheese precursor have been combined, the admixtureis further processed to obtain the desired final soft or firm/semi-hardcheese product. The particular processing steps required, depend in partupon the cheese precursor with which the slurry is mixed. If the cheeseprecursor is a cheese ingredient such as milk or cream, for instance,then the final processing involves completing the cheese manufacturingprocess to form a cheese curd that contains the added slurry, followedby its further processing to yield the final product. If the slurry ismixed with a cheese curd, the slurry/curd mixture can optionally beheated and stretched in a pasta filata type process, or this mixture canbe pressed together to form a final cheese product. Thus, in someinstances, final processing simply involves compressing and molding thecheese curd using conventional cheese compression and molding operationsto form a mass of cheese.

If the process involves a heating of the cheese curd, the still-warmcheese (e.g., at a temperature in the range of about 110-175° F. (43-80°C.)) can be formed into any desired shape depending upon the ultimateintended use. General options include, but are not limited to, 1)forming relatively large pieces of cheese which are packaged; 2)comminuting the cheese into smaller pieces that are packaged withoutfreezing but instead refrigerated; 3) comminuting, packaging andfreezing the cheese, and 4) comminuting, freezing, then packaging thecheese.

In some methods, for instance, the admixture is extruded as a continuousdimensionally flat Ribbon™, which is discharged into a cold sodiumchloride brine channel or tank, for example as described in U.S. Pat.No. 4,339,468 to Kielsmeier or U.S. Pat. No. 5,200,216 to Barz et al.(both of which are incorporated herein in their entirety). The cheeseRibbon™ is sometimes contacted with cold sodium chloride brine (in oneor more tanks or vessels) until its core temperature drops to about 75°F. (24° C.) or below. Then the cooled Ribbon™ can be cut into segmentshaving dimensions suitable for the intended use of the cheese.

Other options include: 1) floating the cheese in a coolant; 2) placingthe cheese on a perforated belt and spraying coolant on the cheesesurface; 3) placing the cheese on a solid belt and spraying coolant onthe underside of the belt; 4) transfer through a cooling chamber; and 5)refrigeration of the heated cheese.

If a string cheese is the desired product [e.g., a cheese having adiameter of about ⅛ to 1.0 inch (0.32 to 2.54 cm.)], the segments of thestring are generally about 1½ to 12 inches (4 to 30.5 cm) long. If thestring cheese is to be baked only while enclosed in pizza crust (e.g.,in a stuffed crust pizza), it typically is unnecessary to age the cheesebefore using it. If desired, the string cheese can be frozen and stored.

The warm cheese can also be molded/extruded into blocks of any of avariety of sizes that are convenient. Some blocks, for example, areabout 4 inches high, 4-8 inches wide, and 4-24 inches long.

If the finished cheese is to be used as an exposed topping for a pizza,then the continuous Ribbon™, typically is rectangular in cross section,and can be cut into loaves, for example having a width of about 4 to 36inches (10 to 92 cm.), a height of about 1/16 to 4 inches (0.15 to 10cm.), and a length of about 4 to 36 inches (10 to 92 cm.). The loavescan then be further cooled in sodium chloride brine, for example to acore temperature in the range of about 26 to 75° F. (−16 to 24° C.), andthen removed from the brine and comminuted, and the pieces individuallyquick frozen, for example by the process described in U.S. Pat. No.5,030,470 to Kielsmeier, et al., which is hereby incorporated herein byreference.

Depending on the composition of the cheese, it may be preferable tostore it for a time [e.g., about 7 to 21 days, at about 35 to 45° F. (2to 7° C.)] after it is removed from the last brine tank and before it iscomminuted and frozen. However, as described in U.S. Pat. No. 5,200,216(Barz et al.), if the process is controlled such that the cooled cheeseremoved from the brine has a moisture content of about 45 to 60 wt. %, amilk fat content of at least about 30 wt. % (dried solids basis), and acombined moisture and wet milk fat content of at least about 70 wt. %,the cheese can be frozen immediately and will still performsatisfactorily when heated under a variety of conditions.

The final processing procedure can also be as described in U.S. Pat. No.5,902,625, which is incorporated herein by reference in its entirety forall purposes.

Methods based on the foregoing processes can be conducted in a batchformat or continuously. Batch methods, for example, involve providingbatches of slurry and cheese precursor that are subsequently combined inbatches. The resulting mixtures are subsequently processed to obtain thedesired final cheese product. The process is then repeated.

In continuous methods, at least the slurry preparation process and theprocess in which the slurry is combined with the cheese precursor isconducted in a continuous process. In some methods, essentially each ofthe steps listed above are conducted continuously such that slurrypreparation, cheese precursor preparation, combining of the slurry andprecursor, optional addition of ingredients, and final processing stepsare all continuously ongoing.

B. Exemplary Methods

FIG. 3A provides a specific example of a method in which a heated slurryand heated cheese mass are combined to form an admixture that cansubsequently be processed to yield a final cheese product, such as asoft or firm/semi-hard cheese product. As noted above, in some instancesthe slurry is heated because this can be useful in increasing the amountof certain ingredients that can be incorporated into the final cheeseproduct and in unmasking the functionality of some ingredients.

This particular method 100 includes a slurry preparation process 105 inwhich a liquid (e.g., water, milk and/or cream) and one or moreingredients are blended 110 together to form the initial slurry. Thepre-mixing process 107 involves cooking/heating 115 the resulting slurryto a temperature of about 90-300° F. This heated slurry is subsequentlysubjected 120 to high shear conditions and then homogenized 125 toobtain a slurry in which the ingredients are of the desired particlesize. Thereafter, the water content of the heated slurry is adjusted130, typically to about 5-95 wt. %. The slurry is transferred to thecombining and mixing state 170 through the use of a pump at thedischarge of a surge hopper, which maintains the slurry at a constantvolume 131. As the slurry is transferred, it may be filtered 132 toremove any large particles formed in the slurry during thecooking/heating step 115 (or other extraneous materials), and alsoexposed to a magnetic field 133 to remove any metal fragments in theslurry generated by metal to metal contact of the moving parts of theprocess equipment.

As further shown in FIG. 3A, the process of providing 150 a cheeseprecursor in this particular method involves several processes to obtaina heated cheese mass. The process is initiated by forming 155 a cheesecurd. Once formed, the cheese curd is heated and kneaded 160 to form aheated cheese mass. During the heating process, the curd is typicallyheated to about 120-155° F.

Once the heated slurry and heated cheese mass have been formed, they aremixed 170 together to form an admixture. This particular method includesa process of mixing in 175 one or more optional ingredients into theadmixture. But as noted above, such additions are optional and not allmethods include this process. Furthermore, although this particularmethod shows the additional ingredients being added to the admixture ofslurry and heated cheese mass, the ingredients could also be added tothe slurry or to the heated cheese mass just prior to mixing.Alternatively, the slurry, heated cheese mass and ingredients can becombined simultaneously. The admixture that is formed is subsequentlyprocessed 180 to form the final soft or firm/semi-hard cheese product.In the particular method depicted in FIG. 3A, final processing 180involves shaping 185 the admixture into a desired form and cooling 190the shaped cheese to form the final cheese product. Although FIG. 3Ashows the final processing step to first involve the shaping processfollowed by the cooling process, this order can be reversed or performedsimultaneously.

Although the particular method illustrated in FIG. 3A shows the slurryand heated cheese mass being mixed together, in other methods the slurryis mixed with another cheese precursor (e.g., milk, coagulum orunprocessed cheese curd). Systems for performing such methods are shownin FIG. 4C.

Another example of a method for preparing soft or firm/semi-hard cheeseis shown in FIG. 3B. In general, method 102 illustrates certain methodsin which a curd or a curd precursor is combined with the slurry, insteadof a heated mass of cheese. In the method illustrated in FIG. 3B, aslurry is provided 105 as described with respect to FIG. 3A. The processof providing 150 a cheese precursor in methods of this type, however,involves providing 151 a curd or curd precursor. In this particularmethod, one or more additional ingredients can be mixed 152 into thecurd or curd precursor, but not all methods include such additions. Thecurd or curd precursor is then combined 153 with the slurry to form anadmixture. The resulting mixture may then be heated and kneaded 171 toform a heated mass of cheese as in a pasta filata process. Method 102also includes a process in which one or more additional ingredients areadded 162 and mixed 172 with the admixture. Here, too, however, not allmethods include such additions. The admixture is then processed 180 toform the final soft or firm/semi-hard cheese product.

The final processing 180 of each of the exemplary methods shown in FIGS.3A and 3B can involve any of the processing options described above orgenerally known in the art. So, for example, in some methods finalprocessing involves individually quick freezing pieces of the cheese asdescribed in U.S. Pat. No. 5,030,470. Other methods involve a same daydice procedure such as described, for example, in U.S. Pat. No.5,200,216. In still other methods, the cheese is not comminuted butformed into blocks that are directly packaged and refrigerated. Those ofskill will recognize that a variety of other processing options areavailable. Further examples are provided in the section on “FinalProcessing” above.

IV. Ingredients

A. General

A number of different types of generally recognized as safe (GRAS)ingredients can be incorporated into the slurry and optionally added atother stages of the overall manufacturing process as described herein.If added at a stage other than the slurry, most ingredients cangenerally be added as a powder or as part of a solution. The ingredientsthat are incorporated are selected, for example, to tailor theperformance, nutritional, and taste characteristics of the final soft orfirm/semi-hard cheese product.

As noted above, some of the ingredients included in the slurry generallyfall into two general categories: 1) ingredients that one seeks toincorporate at relatively high concentration levels; and 2) ingredientsthat need to be heated and/or hydrated to become functionalized, i.e.,to be converted into a form that has the chemical and/or physicalproperties that are important for imparting the desired characteristicsto the final soft or firm/semi-hard cheese product. But a variety ofother ingredients can also be included in the slurry.

Examples of such ingredients include, but are not limited to, nonfat drymilk, a milk protein, an acidity regulator, an acid, an anticakingagent, an antifoaming agent, a coloring agent, an emulsifier, an enzymepreparation, a flavoring agent, a firming agent, a food protein, agelling agent, a preservative, sequestrants, a stabilizer, a starch, athickener, an oil, a fat, a cheese powder, a salt, a nutritionalsupplement, an acid, an enzyme, a neutraceutical, a carbohydrate, avitamin, and a mineral. Examples may further include procream, wheycream, a dairy solid, and foodstuffs of vegetable, fruit and/or animalsource. The foodstuffs may include fruit, vegetables, nuts, meat, andspices, among other foodstuffs.

Examples and additional specific information regarding the types ofingredients that can be incorporated to tailor the performance,nutritional and taste characteristics of the final soft orfirm/semi-hard cheese product follow.

Dairy Solids.

A dairy solid can be added to improve various characteristics of thefinal cheese product such as: firming the cheese, improving waterbinding capacity, improving the melt appearance of the cooked cheese,and/or increasing the blistering of the cooked cheese. Dairy solids thatcan be utilized include, but are not limited to, whey proteinconcentrate, casein hydrolyzate, milk fat, lactalbumin, cream, milkprotein concentrate, milk protein isolate, lactose, casein, whey proteinisolate, hydrolyzed whey protein, denatured whey protein, skim cheesepowder, natural casein isolate, nonfat dry milk, delactose permeate,procream, mixer overflow liquid, and milk minerals. In general, dairysolids can be incorporated into the final product from about 0.5-25 wt.%.

Incorporation of a dairy solid such as nonfat dry milk into a heatedslurry is one approach for obtaining relatively high concentrationlevels in the final product. For example, the dairy solid concentrationin some soft or firm/semi-hard cheeses that are prepared according tothe methods disclosed herein can be at least 11, 12 or 13 wt. %, and caninclude, for example, up to about 16, 17, 18, 19, 20 or 25 wt. % of thefinal product. Thus, the concentration of the dairy solids in the slurryis generally adjusted such that the level of dairy solid in the finalcheese product is about 0.5-25, about 3-18, about 4-16, or about 11-25wt. %. This means that the concentration of the dairy solid in theslurry itself is generally within the range of about 0.5 to 95 wt. %,for example about 10-80%, or about 30-70%, by wt.

Starches.

Incorporating starches into the heated slurry is also beneficial in someinstances because the functionality of some starches is increased whenheated, hydrated and/or subjected to high shear conditions. Oncefunctionalized in this manner, the starch can thicken or gel to bind toproteins in the cheese (e.g., casein). In general, starch can beincorporated into the final product in the range of about 0.5-20 wt. %.

Some methods add starch such that the starch concentration in the finalcheese product is at least 4, 6, 11, 12, 13 or 20 wt. %. Thus, in someinstances, the starch concentration can range from about 4-20 wt. % orfrom about 5-16 wt. % in the final cheese product. This means that thestarch concentration in the slurry itself is typically about 0-95 wt. %,for example about 0.5-50%, or about 1-25% by wt.

A number of different types of starches can be incorporated into thefinal cheese product. Suitable starches include vegetable starches(e.g., potato starch, pea starch, and tapioca) and grain starches (e.g.,corn starch, wheat starch, and rice starch). Specific examples ofsuitable corn starches include dent corn starch, waxy corn starch, andhigh amylose corn starch. The starches can be used individually or incombination.

The starch can be modified or native. Modified food starches differ intheir degree of cross-linking, type of chemical substitution, oxidationlevel, degree of molecular scission, and ratio of amylose toamylopectin. Examples of some commercially-available modified foodstarches that are suitable include Mira-Cleer 516, Pending 200, Purity660, Batterbind S.C., Penbind 100, MiraQuick MGL, Novation 3300, andGel-n-Melt. A suitable commercially-available native (unmodified) starchis Hylon V.

Mira-Cleer 516, from A. E. Staley Company, is a dent corn starch that iscross-linked and substituted with hydroxypropyl groups. Thecross-linking increases its gelatinization temperature and acidtolerance. The hydroxypropyl substitution increases its water bindingcapability, viscosity and freeze-thaw stability. MiraQuick MGL, alsofrom A. E. Staley Company, is an acid-thinned potato starch. The acidthinning breaks amylopectin branches in the starch, creating a firmergel. Batterbind S.C., from National Starch, is a cross-linked andoxidized dent corn starch. Purity 660, also from National Starch, is across-linked and hydroxypropyl substituted dent corn starch. Hylon V,also from National Starch, is an unmodified, high amylose corn starch.Pending 200, from Penwest Foods, is an oxidized potato starch. Theoxidation increases its capacity to bind water and protein. Penbind 100,also from Penwest Foods, is a cross-linked potato starch.

Emulsifiers, Gelling Agents, Stabilizers and Thickeners.

Gums, celluloses, and alginates are some examples of emulsifiers,gelling agents, stabilizers and thickeners. Many of the considerationsthat apply to starches also apply to gums and celluloses. Certain gumsand celluloses, for example, should be hydrated and/or heated to realizetheir full functional characteristics. Heating and hydration alsoenables increased levels of the gums, celluloses, or alginates to beincluded in the final product. Some of the soft or firm/semi-hardcheeses that are provided herein contain at least about 0.01, 0.5 or 3.0wt. % gum, cellulose, or alginate. The products thus generally have agum, cellulose, or alginate concentration of about 0.01-3.0 wt. %. Thismeans that the concentration of the gum, cellulose, or alginate in theslurry itself is typically about 0.02-6.0 wt. % or 0.05-5.0 wt. %.

Different types of celluloses can also be incorporated into the cheese.The cellulose can be either natural or modified. One cellulose orcombinations of different celluloses can be utilized. Types ofcelluloses that can be utilized include, but are not limited to,microcrystalline cellulose, powdered cellulose, methylcellulose,propylene glycol alginate, and sodium alginate. One specific example ofa commercially available modified cellulose is METHOCEL A-15 that isavailable from Dow Chemical Company (Midland, Mich.).

Examples of suitable gums that can be incorporated include, but are notlimited to, xanthan gum, guar gum, konjac flour and locust bean gum.Examples of suitable stabilizers include chondrus extract (carrageenan),pectin, gelatin, and agar.

The total amount of gums and stabilizers included in the final cheeseproduct is typically up to about 0.01, about 0.50, or about 3.0% byweight. More specifically, the amount of gums and/or stabilizers canrange from about 0.01 to 3.0%, from about 0.25 to 2.5%, from about 0.5to 2.0%, or about 0.75-1.5% by weight of the final cheese product. Gumsand stabilizers concentrations in the slurry are typically in the rangeof about 0.02-6.0, or 0.50-5.0 wt. %.

Acidity Regulators, Anticaking Agents, and Firming Agents.

Acidity regulators, anticaking agents, and firming agents of varioustypes can be included in the cheese. Typically, these agents areinorganic salts, but other types of acidity regulators, anticakingagents, and firming agents can also be used. Examples of acidityregulators, anticaking agents, and firming agents may include calciumchloride, tricalcium phosphate, calcium hydroxide, powdered cellulose,disodium phosphate, and potassium hydroxide. These agents are typicallyadded as part of a solution, (but could be used as a powder) either byincorporation in the slurry or in a non-heated liquid that isincorporated into the admixture of the slurry and heated cheese mass.

The total amount of acidity regulators, anticaking agents, and firmingagents incorporated into a slurry is sufficient so the concentration ofthe acidity regulators, anticaking agents, and firming agents in thefinal cheese product is generally up to about 0.05, 1.2, or 3.0% byweight. More specifically, the amount of acidity regulators, anticakingagents, and firming agents can range from about 0.05 to 3.0%, from about0.1 to 2.5%, or from about 0.5 to 2.0% by weight. This means that theconcentration of the acidity regulators, anticaking agents, and firmingagents in the slurry is typically about 2 to 95% by weight.

Sequestrants.

A number of different sequestrants can be incorporated into the finalcheese product. Sequestrants that can be utilized include, but are notlimited to, various phosphate salts (e.g., sodium hexametaphosphate,monosodium phosphate, sodium tripolyphosphate, disodium phosphate,trisodium citrate and potassium phosphate), calcium citrate, calciumgluconate, oxystearin and sorbitol.

The total amount of sequestrant is usually up to about 0.1, 1, or 4% byweight of the final cheese product. So, for example, the amount ofsequestrant in the final cheese product can range from about 0.1 to 4%,from about 0.25 to 3.0%, or from about 0.4 to 2.5% by weight. Theconcentration of the sequestrants in the slurry itself thus is generallyabout 0.1 to 95 wt. %.

Acids.

An acid can be incorporated to adjust the pH of the finished cheese to adesired level. Various acids can be employed; examples of suitable acidsinclude, but are not limited to, adipic acid, lactic acid,glucono-delta-lactone, phosphoric acid, lactobionic acid, hydrochloricacid, acetic acid, or Genlac C, the latter being a blend of water,citric acid, lactic acid, acetic acid and artificial flavors. Acid istypically added to adjust the pH of the finished cheese to a pH fromabout 5-6 is reached, and more typically from pH 5.10-5.70.

If included in the slurry, the acid agent is included in an amountsufficient to adjust the pH of the slurry within the range of about 0.0to 8.0, for example, from about 0.5-6.5, or 1-5.

Cheese Powders.

Cheese powders can also be mixed into the cheese to impart a differentcheese flavor to the finished product. Such powders are typically addedto the heated cheese mass formed during the pasta filata process as apowder rather than as part of the slurry.

Examples of suitable cheese powders include, but are not limited to,Parmesan, cheddar, Monterey Jack, Romano, muenster, Swiss, and provolonepowders. The amount of cheese powder in the finished cheese is generallyabout 0.25 to 10%, and in some instances about 1 to 5% by weight. Cheesepowders are available from a variety of commercial suppliers, including,for example, Armour Foods of Springfield, Ky.

Colorants.

A colorant can be incorporated into the cheese to adjust its naturalcolor. This can be useful, for example, if consumers have a preferencefor a color other than the naturally-occurring color. Examples ofsuitable colorants include annatto, tumeric, titanium dioxide, andbeta-carotene. Colorants may be of both the natural or artificial color.If one wished to color the cheese a red an artificial color such as FD&Cred #40 can be used. Annatto is useful to give mozzarella cheese theappearance of cheddar. This allows one to produce a cheese for pizzabaking that has the desired melt characteristics of mozzarella, but witha different appearance than that of traditional white mozzarellaAnnatto-colored mozzarella can be used as a replacement for cheddarcheese in many food products (e.g., Mexican-style prepared foods).Tumeric imparts a yellowish color to mozzarella, which naturally iswhite. The yellowish color often is preferred by consumers who perceiveit to indicate a “richer” product upon cooking on a pizza. Colorantssuch as annatto and tumeric can be obtained, for example, from ChrisHansens Labs of Milwaukee, Wis.

Colorants can be incorporated into the final cheese product by inclusionin the slurry. If added apart from the slurry, the colorant is generallysprayed onto the heated cheese mass as an unheated solution ordispersion in water. The amount of colorant added is typically in therange of about 0.01 to 2%, based on the weight of the finished cheese.Tumeric, if used, is generally added in an amount of about 0.05 to 0.5%.If annatto is added, it normally is added to about 0.1 to 0.9% byweight.

Flavoring Agents.

Various flavoring agents can also be incorporated into the cheese totailor the flavor profile of the cheese to meet consumer preferences.Suitable flavors for mixing into the heated cheese include, for example,cheddar cheese flavor and parmesan cheese flavor.

Flavoring agents are typically added in an amount such that theconcentration in the final cheese product is within the range of about0.01 to 5 wt. %. If incorporated into the slurry, the concentration ofthe flavoring agent in the slurry is generally is in the range of about0.02 to 5 wt. %.

Non-Dairy Protein Isolate.

A non-dairy protein isolate can also be incorporated into the soft orfirm/semi-hard cheese. It is to alter the texture of the cheese and/orto change the size, color, or integrity of the blisters that are formedwhen the cheese is baked on a pizza, as well as other cookcharacteristics. Examples of suitable non-dairy protein isolatesinclude, but are not limited to, soy protein (sometimes called “soypowder”), gelatin, wheat germ, corn germ, gluten, and egg solids.

The protein isolate is added such that the concentration of the proteinisolate in the final cheese product is up to about 1, 15 or 30 wt. %.The concentration of the protein isolate in the slurry is thus adjustedso the concentration is about 2 to 95% by weight of the slurry.

Oils.

Various oils can also be incorporated into the cheese. They aregenerally added to alter the fatty acid profile and/or cost of thecheese and/or to change the size, color, or integrity of the blistersthat are formed when the cheese is baked, as well as other cookcharacteristics. Examples of suitable oils include, but are not limitedto, vegetable oils, soy bean oil, corn oil, flax seed oil, walnut oil,palm oil, linoleic acid, fish oil, omega 3 fatty acids, and medium chaintriglycerides, among others. Any of the oils may be partially orcompletely hydrogenated. If blended into the initial slurry, the oil isadded in a concentration such that the concentration of the oil in thefinal cheese product is up to about 1.0, 20 or 35 wt. %. Theconcentration of the oil in the slurry is thus adjusted so theconcentration is about 0 to 65, by weight, (e.g., about 5 to 50% wt.) ofthe slurry.

Salt.

Salts of various types, but typically sodium chloride, can be added totailor the flavor of the final cheese. The salt can be incorporated intothe final cheese product by including it in the heated slurry or byadding it in granular form or as an unheated solution apart from theslurry. Regardless of how introduced, the salt concentration in thefinal cheese product is usually added at a level of about 0.1-5 wt. %.When added as an ingredient of the slurry, this means that the saltconcentration in the slurry is generally about 0.0 to 25.0 wt. %, forexample about 0.5-22%, or about 1-18% by wt.

Antifoaming Agents.

Various antifoaming agents can be incorporated to facilitate processing.Examples include, but are not limited to, microcrystalline wax,oxystearin and polydimethylsiloxane.

Carbohydrates.

A variety of simple sugars (e.g., mono- and disaccharides), as well asmore complex carbohydrates can be included in the cheese. Examplesinclude, but are not limited to, glucose, sucrose, and fructose.

Enzymes.

Enzymes may be used to create flavors, texture, melt, and/or otherfunctional characteristics in the final cheese product, and/or in theslurry that can then be transferred to the final cheese product once theslurry and cheese have been mixed together. Examples of such enzymes,and this is not an all inclusive list, would be lipases, proteases,oxidoreductases, and transglutaminase.

Neutraceuticals.

Neutraceuticals may be included to deliver nutrients not normallypresent in cheese. Examples of neutraceuticals include, but are notlimited to lycopene, antioxidants, probiotics, prebiotics,phosphatidylserine, vegetable sterols, immunoglobulins. These productsin particular may be added as part of the slurry or to the mixer (mixer290, FIG. 4B).

V. Slurries and Slurry Preparation Methods

Slurries that are combined with a cheese precursor to produce the softor firm/semi-hard cheese product are also provided. As described, thesecompositions contain one or more of the ingredients or ingredientslisted in the preceding section. In general, the concentration of theseingredients is sufficient to obtain a final soft or firm/semi-hardcheese product having the desired concentration of the ingredient (seepreceding section). More specifically, the ingredient concentrations arein the range listed above.

The slurries utilized to prepare the soft or firm/semi-hard cheeses thatare provided typically are water-based compositions. But some slurriesalternatively or in addition include another liquids such as milk orcream. The water in some compositions typically accounts for from about5-95% of the slurry by weight. Slurries may also include emulsions ofwater and oil and/or fat.

The slurries are optionally processed to be in a form that mixes wellwith another cheese ingredient (e.g., curd or heated cheese mass), thatpromotes dissolution of ingredients and/or that confers the desiredprocessing or performance characteristics. Details regarding the slurrypreparation process are described above, including FIGS. 3A and 3B andaccompanying text.

One example of a useful base slurry is one that contains cream, nonfatdry milk and water. To obtain high concentrations on nonfat dry milk, itcan be useful to include an acid and salt. Above about 60% nonfat drymilk, for example, the slurry can get very viscous and thus difficult topump through the slurry processing system described above. By addingacid as a processing aid, and salt to the slurry, the viscosity can bereduced sufficiently such that the slurry containing the desired highlevels of nonfat dry milk can be transported through the processingsystem. Although any acid and salt could be added elsewhere during theprocess, inclusion in the slurry can be useful for the reasons justlisted.

To reiterate a point made earlier, slurries can be used to providevarious benefits during the cheese manufacturing process, includingincreased yield. Nonfat dry milk contains about 27 wt. % casein proteinand about 73% other components (e.g., ash, lactose, whey protein, etc.).If the nonfat dry milk is added to the milk at the beginning of thecheese manufacturing process, much of the casein becomes incorporatedinto the cheese, but much, or all, of the other components are lost.Using slurries and methods such as provided herein, essentially all ofthe casein and whey protein can be incorporated into the final cheeseproduct, thus significantly increasing the yield of the overall process.

VI. Systems for Preparing Soft or Firm/semi-Hard Cheese Products

FIG. 4A depicts one example of a generalized system 200 that can be usedto carry out the foregoing methods to prepare the soft or firm/semi-hardcheeses that are described herein. This exemplary system includes thefollowing subsystems: (1) a slurry preparation system 205; (2) a cheeseprecursor preparation system 260 that is in fluid communication withslurry preparation system 205; and (3) a final processing system 300that is in communication with cheese precursor preparation system 260.The slurry preparation system includes the equipment necessary toprepare the slurry that contains the one or more ingredients selectedfor inclusion in the final cheese product. The cheese precursorpreparation system generally includes the equipment and devices requiredto prepare a cheese precursor, and can include a mixer or related deviceto combine the slurry with the precursor. The final processing systemincludes the equipment to convert the admixture of the slurry and cheeseprecursor into the desired final product.

A wide variety of different systems have this general design. Althoughspecific examples of such systems are described below, it should beunderstood that these systems are only examples and not intended to bean exhaustive list of the types of systems that can be used to carry outthe cheese processing methods that are described herein or of the typeof systems that can be used to prepare the type of soft orfirm/semi-hard cheeses that are disclosed herein.

One exemplary system that can be used to perform the methods that aredisclosed herein is shown in FIG. 4B. This particular system 202 is foruse primarily in methods in which a slurry is combined with a heatedmass of cheese (see, e.g., FIG. 3A). The cheese precursor preparationsystem 260 of system 200 generally includes a curd preparation subsystem261 that is connected to cooker/kneader 270 by transfer tube 268.Cooker/kneader 270 is connected in turn by transfer tube 269 to mixer290, which is also in communication with slurry preparation system 205via transfer tube 255. In operation, curd is thus prepared in curdpreparation subsystem 261 and can be transported through transfer tube268 into cooker/kneader 270, where the cheese curd is heated and kneadedto form a heated cheese mass. This mass can then be combined with theslurry prepared in slurry preparation system 205. The cheese precursorpreparation system 260 also includes dispenser 251 which is connected tocurd preparation system 261. Thus, additional control over thecomposition and preparation of the final cheese product can be achievedby adding ingredients from dispenser 251 to compositions in the cheesecurd preparation system 261 via transfer tube 252. But not all systemsinclude such a dispenser.

The slurry preparation system 205 of system 200 generally includes theequipment necessary to blend, heat, shear, homogenize and adjust thewater content of the slurry to obtain the desired slurry composition.More specifically, system 205 includes a blender 210 and cooker 220 thatare connected to one another via transfer tube 215. The transfer tube215 may include a pump stuffer that moves the slurry to the cooker 220.The pump stuffer may include two augers that move the slurry and ahopper that takes up the slurry into the augers from the blender 210. Aliquid (e.g., water, milk and/or cream) and one or more slurryingredients can thus be introduced into blender 210, where they areblended together to form an initial slurry. This resulting slurry canthen be transported into cooker 220, where the slurry is heated to forma heated slurry. Slurry preparation system 205 in this system alsoincludes slurry mixing and moisture control subsystem 208. Theparticular subsystem 208 shown in FIG. 4B includes shear pump 230,homogenizer 240 and evaporator 250. Subsystem 208 is in communicationwith cooker 220 and mixer 290.

In the particular subsystem shown in FIG. 4B it is shear pump 230 ofsubsystem 208 that establishes the link with cooker 220, as shear pump230 is connected to cooker 220 via transfer tube 225. Shear pump 230 isalso connected to homogenizer 240 by transfer tube 235, which in turn isconnected to evaporator 250 by transfer tube 245. Subsystem 208 isconnected to mixer 290 by transfer tube 255, which connects evaporator250 and mixer 290.

Thus, heated slurry from cooker 220 can flow into shear pump 230 viatransfer tube 225, where the slurry is subjected to shear conditions.The sheared slurry can subsequently be transferred to homogenizer 240through transfer tube 235, where the slurry and the ingredient(s) itcontains are homogenized. The resulting homogenized slurry can then flowthrough transfer tube 245 into evaporator 250. Evaporator 250 adjuststhe moisture content so it is within the desired range. The final slurrythen flows from evaporator 250 into mixer 290 via transfer tube 255.

The heated slurry from slurry preparation system 205 can then becombined with the heated cheese mass from cheese precursor preparationsystem 260 in mixer 290. Ingredients can also optionally be introducedinto mixer 290 from additive dispenser 286, which is in communicationwith mixer 290 through transfer tube 287. The admixture formed in mixer290 can then be transported via tube 291 and processed in finalprocessing system 300. Final processing system 300 as depicted in thisparticular system includes extruder 305 that is connected to coolingsystem 315 by tube 310. Various other final processing systems, however,can also be utilized as described herein.

It will be appreciated by those of ordinary skill in the art thatcertain units within slurry preparation system 205 (e.g., cooker 220,shear pump 230, homogenizer 240 and evaporator 250) need not beincluded. Most slurry preparation systems include a blender to blend theliquid and ingredients together. But the slurry preparation system caninclude none of the other units just listed (i.e., cooker, shear pump,homogenizer and evaporator), individual units, combinations of multipleunits or all the units depending upon the particular requirements of theapplication. It should also be understood that these units can bearranged in a variety of other configurations. For instance, althoughshown as separate units in FIG. 2C, shear pump 230 and homogenizer 240can be part of a single unit in other systems. Other combinations thatcan optionally be utilized in still other systems are those in whichcooker 220 and shear pump 230 are part of the same unit, and systems inwhich cooker 220, shear pump 230 and homogenizer 240 are all part of thesame integrated unit.

The order in which cooker 220, shear pump 230 and homogenizer 240 appearin FIG. 4B can also be altered in other systems such that all thevarious permutations are possible. Examples of optional arrangementsthat can be utilized in other systems include: 1)cooker-homogenizer-shear pump, 2) shear pump-homogenizer-cooker, 3)shear pump-cooker-homogenizer, 4) homogenizer-shear pump-cooker, 5)homogenizer-cooker-shear pump, and the other various permutations.

Another exemplary system is illustrated in FIG. 4C. This figure depictsa system 203 that would typically be used to conduct methods in whichthe slurry is mixed with a cheese curd or curd precursor (see, e.g.,FIG. 3B). The resulting admixture can then be heated and kneaded as in apasta filata type process.

The slurry preparation system 205 for system 203 is as described forsystem 202. The cheese precursor preparation system 260 includes variousunits utilized in the preparation of cheese curd. Cheese precursorpreparation system 260 in the particular system shown in FIG. 4C thusincludes, for instance, curd preparation system 261, which includes curdcontainers 262 of cheese ingredients (e.g., milk, starter and cream) ormixtures thereof (e.g., cheese vat), a system for forming coagulum 264,and containers 266 of curd. Cheese precursor preparation system 260 alsoincludes mixer 290, but some systems omit this mixer. In operation,ingredients or mixtures thereof in containers 262 can be moved to thesystem for making the coagulum 264 via transfer tube 263. The coagulumcan subsequently be transported from system 264 to container 266 throughtube 265. The curd can then be moved from containers 266 to mixer 290through transfer tube 267. Curd preparation system 261 may also includeingredient dispenser 251, which can be connected to ingredientcontainers 262, coagulation system 264 and/or curd container 266 viatransfer lines 253 a, 253 b, 253 c, respectively. This thus allows theoption of adding ingredients at each of these stages of the process.

In system 203, slurry can be transported through lines 255 and lines 256a, 256 b, and/or 256 c such that the slurry becomes combined with theingredients or mixtures in containers 262, the coagulum in coagulationsystem 264, and/or the curd in containers 266. System 203 is designed toallow for various processing options once the slurry and cheeseprecursor are combined to allow for a curd/slurry admixture. One option,for example, is to transport the admixture through tube 291 to the finalprocessing system 300 to form the final product. In an alternativeconfiguration, however, curd preparation system 261 is in communicationwith cooker 270 via tube 267, which in turn is connected to mixer 290via tube 267. Mixer 290 may be connected to final processing system 300by transfer tube 291. Alternatively, the transfer tube 291 may divertthe flow of the admixture between coloring units 293 and 294. Coloringunit 293 may add coloring (e.g., orange coloring) to the admixture togive it the appearance of, for example, cheddar cheese, while coloringunit 294 may add no color and leave the cheese substantially white incolor. The entire admixture may be diverted through one or the othercoloring units 293 and 294, as well as being adjustable to split theadmixture between the coloring units to create, for example, a cheesecombination from the admixture.

Another option is for the admixture to be moved to cooker 270 throughtube 267. Once the admixture has been heated and kneaded, the resultingheated admixture can be transported to mixer 290 via tube 288. This thusallows additional ingredients to be introduced into the admixture fromdispenser 286 as described with respect to system 202. Once theadditional ingredients are mixed in with the slurry and cheese precursoradmixture, the resulting admixture can be transported to finalprocessing system 300 through tube 291.

Embodiments of the system also include the introduction of ingredientsin parallel and serial fashion. Referring to FIG. 4D, for example, asystem 400 is shown with a configuration that has transfer tube 321diverting the admixture from mixer 320 into two mixers 290 a and 290 b.Transfer tubes 287 a and 287 b connect the mixers 290 a and 290 b toingredient dispensers 286 a and 286 b, respectively, which can add thesame or different ingredients to admixtures. The final admixtures maythen be sent through transfer tubes 291 a and 291 b to final processingsystems 300 a and 300 b, respectively. In another example, FIG. 4E showssystem 410 that has one or more ingredients added sequentially fromingredient dispensers 286 and 332. In system 410, a first ingredient (orfirst plurality of ingredients) is dispensed to mixer 290 fromingredient dispenser 286 via transfer tube 287. The resulting admixturemay be sent through transfer tube 336 to mixer 330, where one or moreadditional ingredients may be added by a second ingredient dispenser 332coupled to the mixer 330 via transfer tube 334. The additionalingredients may be the same as, or different than the first ingredient(or first plurality of ingredients). The resulting admixture formed inmixer 330 may be sent through transfer tube 338 to the final processingsystem 300.

The final processing system utilized in these exemplary systems canvary, but can include a pre-brine tank that includes super cold sodiumchloride brine into which molten cheese or cheese ribbons can flow. Acutter can cut the cheese into loaves as the cheese ribbon exits thepre-brine tank. The cooled and salted loaves are then transferred to amain brine tank where they stay until removed by a conveyor. Anexemplary system of this general design is described in U.S. Pat. No.5,902,625, which is incorporated herein by reference in its entirety forall purposes.

A variety of different types of equipment can be utilized in theforegoing systems. For example, different types of blenders can be usedto mix the ingredients together to form the initial slurry. In general,the blender simply needs to be capable of mixing relatively viscousfluids. One common blender is a twin-screw mixer or extruder such as iscommon in the food industry. Ribbon blenders or pipelines that include aseries of pumps and static mixers can also be utilized.

The cooker used in the slurry preparation systems can be of varioustypes, including the lay-down cooker, swept surface heat exchanger,agitated direct heating pipeline cooker. The cookers are capable ofheating a slurry of the compositions defined herein to temperaturesranging from about 90-293° F. Specific examples of suitable cookersinclude the RotaTherm™ cooker available from Gold Peg International Pty.Ltd. (Moorabbin, Vic, Australia) or the FusionCooker™, available fromBlentech Corporation, Rohnert Part, Calif.), the continuous mixer fromREADCO Manufacturing (York, Pa.), or single or Evolum 145 twin screwextruders from Clextral Inc. (Tampa Fla.). The cookers can heat theslurry by convection (e.g., a heated blanket surrounds the cooker),conduction, or radiation, or by directly injecting steam into thecooker.

Various types of shear pumps can be utilized. Suitable types of shearpumps include inline mixers, or colloid mills. Examples of pumps thatcan be used include Silverson in-line mixer (East Longmeadow, Mass.) andStephan cooker (Stephan Machinery Corporation (Columbus, Ohio), or acolloid mill supplied by Waukesha Cherry Burrell (Charlotte, N.C.). Theshear pump should be capable of generating a shear rate of at least10,000 to 500,000 s⁻¹.

A number of homogenizers are also suitable for use in the systems thatare provided. Examples of homogenizers that can be used include thosemanufactured by APV Gaulin (Kansas City, Mo.) and Waukesha CherryBurrell (Charlotte, N.C.). Evaporators of different types can also beutilized. In general, the evaporator should be able to handle relativelyviscous solution. Flash vacuum vessels are one example of a suitableevaporator. Evaporators of this type are available from Invensys APV(Lake Mills, Wis.) or De Dietrich Process Systems (Bridgeton, Mo.). Somesystems include a feedback system that is connected to the evaporator(e.g., a near infrared monitor). This system may include a sensor thatcan monitor the moisture level in the slurry coming from the evaporatorand send a signal to the evaporator signaling the evaporator toincrease, decrease or maintain the level at which water is removed fromthe slurry so the desired moisture content in the slurry is achieved.

For systems in which the cheese curd is heated and kneaded, a number ofdifferent kneading mixers can be used to form the heated mass of cheese.One exemplary device for performing this operation is a single ortwin-screw mixer or a twin-screw extruder, either fitted for steaminjection or having a heated jacket, or a combination of both. Whenusing a twin-screw mixer or extruder to perform the heating andkneading, the screws (i.e., augers) are typically arranged so theyoverlap, to insure thorough mixing.

VII. Soft or Firm/semi-Hard Cheeses

The methods that are described herein can be utilized to prepare soft orfirm/semi-hard cheeses that contain one or more of the ingredients atthe concentration ranges described herein. As indicated above, some ofthe methods that are disclosed herein can be utilized to manufacturesoft or firm/semi-hard cheeses that contain ingredients that becomefunctionalized when included in a slurry and are subject to heatingand/or hydration. Some of the soft or firm/semi-hard cheeses can alsoinclude relatively high concentrations of certain ingredients. As setforth above, some of the soft or firm/semi-hard cheeses can contain atleast 10, 11, 12, 13 or 14 wt. % of one or more of the ingredientslisted above. So, for instance, some of the cheeses that are providedhave one, two, three or more of the following characteristics.

Some of the soft- or semi soft cheeses that are provided arecharacterized by having a starch concentration of at least 10, 11, 12,13 or 14 wt. %. So, for example, some of the soft or firm/semi-hardcheeses have a starch concentration of about 12-14 wt. %, others astarch concentration of about 14-16 wt. %, and still others a starchconcentration of about 16-20 wt. %.

A characteristic of other soft or firm/semi-hard cheeses that areprovided is that they have a dairy solid (e.g., nonfat dry milk)concentration of at least 10, 11, 12, 13 or 14 wt. %. Other soft orfirm/semi-hard cheeses have dairy solid concentrations up to about 16,17, 18, 19, or 20 wt. %. Some soft or firm/semi-hard cheeses of thistype thus have dairy solid concentrations of about 12-14 wt %. Othersoft or firm/semi-hard cheeses have a dairy solid concentration of about14-16 wt. %, or about 16-20 wt. %.

Other soft or firm/semi-hard cheeses that are provided have a celluloseconcentration of at least 0.01, 0.5, or 3.0 wt. %. Such cheeses, forinstance, thus have cellulose concentrations that range from about0.01-3.0, or 0.25-2.5, or 0.5-2.0 wt. %.

The soft or firm/semi-hard cheeses that are provided typically have aprotein content of about 10-40 wt. %, a moisture content of about35-65%, and a fat content of about 0-60% on a dry basis (FDB). Theactual composition varies somewhat depending upon the particular type ofcheese that is to be produced. For certain soft or firm/semi-hardcheeses (e.g., mozzarella cheeses) that are provided, the milk fatcontent is at least 45% by weight of solids and the moisture content isabout 52-60 wt. %. The low-moisture soft or firm/semi-hard cheeses (alsosometimes referred to as low-moisture mozzarella cheeses) that areprovided generally have a minimum milk fat content of 45% by weight ofsolids and a moisture content that is about 45-52 wt. %. Part skim-milksoft or firm/semi-hard ripened and unripened cheeses (also called partskim mozzarella cheeses) that are provided, in contrast, have a milk fatcontent that ranges from about 30-45% by weight of solids and a moisturecontent that is about 52-60 wt %. The low-moisture, part-skim soft orfirm/semi-hard ripened and unripened cheeses (also referred to aslow-moisture, part skim mozzarella cheeses) that are provided usuallyhave a milk fat content of about 30-45% by weight of the solids and amoisture content of about 45-52 wt %. The foregoing moisture percentagesare for bound plus free water, i.e., the percent of weight lost when thecheese is dried for 17 hrs±1 hr in a 100° C. oven.

The soft or firm/semi-hard cheeses that are provided can be in a varietyof different forms including loaves, Ribbons™, comminuted forms (e.g.,diced or shredded forms) and other forms known in the art. The pH of thesoft or firm/semi-hard cheese generally ranges from about 5.00 to about6.00, such as about 5.10 to about 5.90.

VIII. Food Products and Methods of Manufacturing Such Food Stuffs

The soft or firm/semi-hard cheeses that are provided can be utilized inessentially any baking application that involves the use of soft orfirm/semi-hard cheese and can be incorporated into a wide variety offoodstuffs and food products. The soft or firm/semi-hard cheeses, forinstance, can be included as an ingredient in a variety of conveniencefoods, including entrees, snack foods and appetizers.

The term “food product” is intended to broadly encompass any type offood to which one can add cheese. Examples of suitable types of foodsinto which the provided cheeses can be added, include, but are notlimited to: cereal-based products; poultry, beef, pork or seafood-basedentrees; potatoes; vegetables; fruit; candy; and nuts. The cereal-basedproducts can be of diverse types including, for instance, pizzas,burritos, dough-enrobed sandwiches, hand-held foods, breads, bagels,pastries, and grain-based snack foods (e.g., crackers and pretzels). Thecheese can be included with a variety of different forms of potatoes,including, chips, French fries, hash browns, and strings. Likewise,vegetables of various types can be combined with the cheeses that areprovided. Exemplary vegetables include, mushrooms, zucchini, peppers(e.g., jalapenos) and cauliflower.

The soft or firm/semi-hard cheeses can be incorporated into the foodproduct, layered onto or in the food product or used as a coating. Onecommon use, for example, is as an exposed cheese on a pizza or as thestring cheese rolled in the outer lip of a pizza crust (a so-called“stuffed crust pizza”).

As those skilled in the art will recognize, the foregoing list is simplyillustrative and is not intended to be an exhaustive list of the typesof foods that can be combined with the cheeses that are provided herein.

The soft or firm/semi-hard cheeses that are provided are suitable foruse in essentially any type of cooking including convection heating,steam injection heating and microwave heating, for example. In somemicrowave heating applications, for example, the food product is exposedto microwave energy in an amount and for a duration sufficient to heatand melt the cheese, whereby the cheese melts to form a uniform mass ofcheese. The cheeses can generally be heated in a variety of microwaves,such as microwaves having wattages of 400-1000 watts, or full powermicrowave ovens of 650-850 watts that are common home microwave ovens.The cheeses can be cooked over a range of cooking times such as from 0.5to 20 minutes, or 0.5-10 minutes, or 2-5 minutes, which are the typicalmicrowave cook times used to prepare frozen or refrigerated entrees andappetizers.

The soft or firm/semi-hard cheeses that are disclosed herein can becombined with food products such as those just listed using any of avariety of methods. For example, the food product can be dipped inmelted cheese. Alternatively, the cheese can be sprinkled or layeredonto the food product using conventional food processing equipment. Insuch processes, the cheese is typically first comminuted to formrelatively small pieces of cheese or shredded cheese. Once the cheesehas been combined with the food product, the resulting food product canoptionally be refrigerated or frozen for future sale or use.

The following examples are presented to illustrate certain aspects ofthe methods and soft or firm/semi-hard cheeses that are disclosedherein. These examples should not be construed to limit the scope of theclaims.

EXAMPLES

Three different levels of nonfat dry milk (NDM) (2.5%, 6.0%, and 12.0%,by weight) were incorporated into Mozzarella cheese, either directly inpowder form (see Examples a, c, and e) or as part of a slurry added tothe cheese curds (see Examples b, d, and f). The slurry compositionsincluded the NDM, as well as salt, cream, water, and gluconic acid,where the gluconic acid is added to the slurry as a processing aid tocause a reduction in slurry viscosity before cooking, making the slurryeasier to pump through the cooker and other system equipment. Therelative amounts of the slurry ingredients used in the slurry examples(i.e., Examples b, d, and f) are summarized in Table 1:

TABLE 1 Slurry Composition % GLUCONIC Treatment % NFDM % SALT % CREAM %WATER ACID (50% TS) Example b. 54.19 5.8 29.63 10.38 0 2.5% NDM added asslurry Example d. 54.19 5.8 29.63 7.05 3.33 6.0% NDM added as slurryExample f. 54.19 5.8 21.05 13.96 5.00 12.0% NDM added as slurry

The final cheese product included conventional starter cultures and thecomposition targets were 49.0% moisture, 40.0 FDB, 5.35 pH, and 1.80%salt. Ribbon™ cheese (7×9×2-inches) was extruded and the packaged cheesesamples were stored at 35° F. (1.7° C.) for 14 days before beingshredded on an Urchell CC shredder (Urchell Laboratories, Inc., Indiana,USA) into cuts with approximate dimensions of 1.25″-3″ by 0.20″ by0.095″. The cuts were individually frozen and stored at −20° F.Two-pound samples of cheese were removed, thawed at 35° F. (1.7° C.) andmelted on two different types of pizza, including a conveyor-bake pizza(Middleby Marshall oven at 420° F. (215.6° C.) for 6.5 minutes) composedof 7-oz of cheese on a regular pizza crust with 4-oz of pizza sauce. Thecheese was also melted on a frozen pizza composed of 5.6-oz of frozencheese placed on a ready-made crust with 3-oz of sauce and frozen for 24hrs prior to melting in a home oven at 425° F. for 19 minutes.

The shred cut qualities and melt grades of the cheeses produced inExamples a-f were then measured. The melt grade measurements of thecheeses on the service oven pizzas and cooked frozen pizzas includedcomparisons of the blister color, blister %, blister size, melt,stretch, and oiling-off. The melt grade measurements were made with a20-point scale, with 10 being the best grade, while 1 is too little, and20 is too much. Table 2 summarizes the melt grade grading system:

TABLE 2 Melt Grade Grading System NONE SLIGHT MODERATE DEFINITEPRONOUNCED Score 1 to 4 5 to 8  8 to 12 12 to 16 16 to 20 Blister %0-10% 10-25% 25-50% 50-75% >75% Blister Size  ⅛ to ¼′  ⅜ to ½′ ⅝ to ¾′ ⅞to 1′   >1′ Blister Color Light Golden Golden to Light Golden Brown DarkBrown Black Oiling Off None Even sheen over cheese Some minor areasNoticeable collection areas Entire surface heavily surface with slightcoated with oil pooling Meltdown Cheese does not fuse Appears fusedtogether Cheese Cheese is slightly soupy Cheese is very runny, togetherafter cooking but shows minor jigsaw completely fused and sauce appearsto bleed soupy and appears weak appearance together through in bodyStretch  0 to 1′ 1½ to 3′    3 to 5′ 5 to 7′ >7′

The shred quality measurements of the cheeses included comparisons ofshred quality and shred compaction. These measurements were made on a4-point scale with 1 being the best, and 4 being the least acceptable.Table 3 summarizes the results of the melt grade and shred qualitymeasurements for Examples A-F.

TABLE 3 Shred Quality and Melt Grades for Examples a-f Food ServicePizza Shred Cut Quality Blister Blister Oiling Frozen Pizza ShredBlister % Size Color Off Melt Stretch Blistering Melt Stretch CompactionQuality Example a. 5 2 10 3 9 11 2 8 9 1.0 1.0 2.5% NDM added as powderExample b. 6 2 10 3 10 13 3 8 11 1.0 1.5 2.5% NDM added as slurryExample c. 3 1 14 4 10 12 1 7 8 1.5 2.0 6.0% NDM added as powder Exampled. 6 2 12 3 9 10 1 7 8 1.5 2.0 6.0% NDM added as slurry Example e. 4 215 3 12 8 3 12 6 2.0 2.5 12.0% NDM added as powder Example f. 3 1 16 313 9 1 9 5 2.0 3.0 12.0% NDM added as slurry

FIGS. 5A-B show the difference in the quality of the final cheeseproducts when the NDM is added directly as a powder to the cheese curdversus adding the NDM as a component of a liquid slurry. Adding the drypowder NDM at both the 6% and 12% levels causes powdered lumps in thefinished cheese as shown in FIG. 5A. The lumps give the cheese aninferior taste and feel, and can also damage dicer blades that are usedto shred the cheese. In contrast, a slurry that is added to cheesehaving NDM at the same levels (i.e., 6% and 12% by wt. NDM in thefinished cheese) results in a smooth, homogenous finished cheese asshown in FIG. 5B.

It is understood that the examples and embodiments described herein arefor illustrative purposes only and that various modifications or changesin light thereof will be suggested to persons skilled in the art and areto be included within the spirit and purview of this application andscope of the appended claims. The cheeses of the present invention maybe made by the methods described herein, or by any other method thatproduces a finished cheese product having the same physical or chemicalproperties as the present cheeses. All publications, patents and patentapplications cited herein are hereby incorporated by reference in theirentirety for all purposes to the same extent as if each individualpublication, patent or patent application were specifically andindividually indicated to be so incorporated by reference.

What is claimed is:
 1. A soft or firm/semi-hard ripened or unripenedcheese product that has a native or modified starch and one or moreadditional ingredients chosen from a non-fat dry milk, a milk protein,an acidity regulator, an acid, an anticaking agent, an antifoamingagent, a coloring agent, an emulsifier, an enzyme preparation, aflavoring agent, a firming agent, a food protein, a gelling agent, apreservative, sequestrants, a stabilizer, a thickener, an oil, a fat, acheese powder, a salt, a nutritional supplement, an acid, an enzyme, aneutraceutical, a carbohydrate, a vitamin, and a mineral, wherein thestarch, and additional ingredients have a combined concentration ofgreater than 10%, by weight of the cheese product.
 2. The cheese productof claim 1, wherein the cheese product comprises two or more of theadditional ingredients.
 3. The cheese product of claim 1, wherein thesoft of firm/semi-hard ripened or unripened cheese product comprises apata filata cheese.
 4. The cheese product of claim 3, wherein the patafilata cheese comprises mozzarella cheese.
 5. The cheese product ofclaim 1, wherein the native or modified starch and the additionalingredients have a combined concentration greater than 10 wt. % of thecheese product.
 6. The cheese product of claim 1, wherein the native ormodified starch is chosen from potato starch, pea starch, tapioca, cornstarch, wheat starch, and rice starch.
 7. The cheese product of claim 6,wherein the corn starch is further chosen from dent corn starch, waxycorn starch, and high-amylose corn starch.
 8. The cheese product ofclaim 1, wherein one of the additional ingredients that makes the cheeseproduct is the non-fat dry milk.
 9. The cheese product of claim 1,wherein the cheese has one or more of the following characteristics: (i)a starch concentration of about 0.5 to about 20 wt. %; (ii) a non-fatdry milk concentration of about 0.5 to about 25 wt. %; or (iii) a gum orcellulose concentration of about 0.5 to about 20 wt. %, wherein thecheese product comprises a block cheese, a ribbon cheese, a stringcheese, a comminuted cheese, a diced cheese, or a shredded cheese. 10.The cheese product of claim 1, wherein the cheese product has a moisturecontent of about 45 to 60 wt. %.
 11. A soft or firm/semi-hard ripened orunripened cheese product that has at least one ingredient chosen from:(i) a native or modified starch; (ii) non-fat dry milk; and (iii) a gumor cellulose, wherein the soft or firm/semi-hard ripened or unripenedcheese product further includes one or more additional ingredientschosen from a milk protein, an acidity regulator, an acid, an anticakingagent, an antifoaming agent, a coloring agent, an emulsifier, an enzymepreparation, a flavoring agent, a firming agent, a food protein, agelling agent, a preservative, sequestrants, a stabilizer, a thickener,an oil, a fat, a cheese powder, a salt, a nutritional supplement, anacid, an enzyme, a neutraceutical, a carbohydrate, a vitamin, and amineral, and wherein the at least one ingredient and the additionalingredients have a combined concentration of greater than 10%, by weightof the soft or firm/semi-hard ripened or unripened cheese product. 12.The cheese product of claim 11, wherein the cheese product includes atleast two of the ingredients (i)-(iii).
 13. The cheese product of claim11, wherein the cheese product includes all three of the ingredients(i)-(iii).
 14. The cheese product of claim 11, wherein the native ormodified starch is chosen from potato starch, pea starch, tapioca, cornstarch, wheat starch, and rice starch.
 15. The cheese product of claim11, wherein the gum or cellulose is chosen from microcrystallinecellulose, powdered cellulose, methylcellulose, propylene glycolalginate, sodium alginate, xanthan gum, guar gum, konjac flour, andlocust bean gum.
 16. The cheese product of claim 11, wherein thestabilizer is chosen from carrageenan, pectin, gelatin, and agar. 17.The cheese product of claim 11, wherein the cheese product is a patafilata cheese.
 18. The cheese product of claim 14, wherein the cheeseproduct is mozzarella cheese.
 19. The cheese product of claim 11,wherein the cheese product is chosen from a block cheese, a ribboncheese, a string cheese, a comminuted cheese, a diced cheese, and ashredded cheese.
 20. A pasta filata cheese that has at least oneingredient chosen from: (i) a native or modified starch; (ii) non-fatdry milk; and (iii) a gum or cellulose, wherein the pasta filata cheeseproduct further includes a dairy solid other than the non-fat dry milk,and wherein the at least one ingredient and the dairy solid have acombined concentration of greater than 10%, by weight of the soft orfirm/semi-hard ripened or unripened cheese product.
 21. The pasta filatacheese of claim 20, wherein the dairy solid is chosen from whey proteinconcentrate, casein hydrolyzate, milk fat, lactalbumin, cream, milkprotein concentrate, milk protein isolate, lactose, casein, whey proteinisolate, hydrolyzed whey protein, denatured whey protein, skim cheesepowder, natural casein isolate, delactose permeate, procream, andminerals derived from milk.
 22. The pasta filata cheese of claim 20,wherein the native or modified starch is chosen from potato starch, peastarch, tapioca, corn starch, wheat starch, and rice starch.
 23. Thepasta filata cheese of claim 20, wherein the gum or cellulose is chosenfrom microcrystalline cellulose, powdered cellulose, methylcellulose,propylene glycol alginate, sodium alginate, xanthan gum, guar gum,konjac flour, and locust bean gum.
 24. The pasta filata cheese of claim20, wherein the pasta filata cheese includes a sequestrant chosen from aphosphate salt, a calcium salt, oxystearin, and sorbitol.
 25. The pastafilata cheese of claim 24, wherein: (i) the phosphate salt sequestrantis chosen from sodium hexametaphosphate, monosodium phosphate, sodiumtripolyphosphate, disodium phosphate, trisodium citrate, and potassiumphosphate; and (ii) the calcium salt sequestrant is chosen from calciumcitrate and calcium gluconate.
 26. The pasta filata cheese of claim 20,wherein the pasta filata cheese includes an acid chosen from adipicacid, lactic acid, glucono-delta-lactone, phosphoric acid, lactobionicacid, hydrochloric acid, acetic acid, and genlac C.
 27. The pasta filatacheese of claim 20, wherein the pasta filata cheese includes a non-dairyprotein isolate chosen from soy protein, gelatin, wheat germ, corn germ,gluten, and egg solids.
 28. The pasta filata cheese of claim 20, whereinthe pasta filata cheese includes a neutraceutical chosen from lycopene,an antioxidant, a probiotic, a prebiotic, phosphatidylserine, avegetable sterol, and an immunoglobulin.
 29. The pasta filata cheese ofclaim 20, wherein the pasta filata cheese comprises a block cheese, aribbon cheese, a string cheese, a comminuted cheese, a diced cheese, ora shredded cheese.
 30. The pasta filata cheese of claim 20, wherein thepasta filata cheese has a moisture content of about 45 to 60 wt. %.